1. DL manuals
  2. Suzuki
  3. Other
  4. 250
  5. Service Manual

Suzuki 250 Service Manual

Other manuals for 250: Brochure, Service Manual

Summary of 250

  • Page 1

    Group index general information 1 periodic maintenance 2 engine 3 drive train 4 fuel system 5 lubrication system 6 chassis 7 electrical system 8 servicing information 9 foreword this manual contains an introductory description on the suzuki lt-z250 and procedures for its inspec- tion, service and ov...

  • Page 2: Partshark.Com

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm partshark.Com 877-999-5686.

  • Page 3: Supplements

    03 engine.Book page 105 tuesday, february 28, 2006 3:03 pm supplements lt-z250k5 ( 05-model) 10 lt-z250k6 ( 06-model) 11 12 lt-z250k7 ( 07-model) lt-z250k8 ( 08-model) 13 14 lt-z250k9 ( 09-model) partshark.Com 877-999-5686.

  • Page 4: How To Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 5: Partshark.Com

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply thread loc...

  • Page 6: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 7: General Information

    1 general information 1-1 general information contents warning/caution/note .........................................................................1- 2 general precautions ...........................................................................1- 2 suzuki lt-z250k4 (2004-model) ...................

  • Page 8: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ! Indicat...

  • Page 9: Partshark.Com

    General information 1-3 " * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use...

  • Page 10: Serial Number Location

    1-4 general information suzuki lt-z250k4 (2004-model) right side left side * difference between photographs and actual vehicles depends on the markets. Serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the left side of the rear frame pipe. The e...

  • Page 11: Break-Ln Procedures

    General information 1-5 engine oil (for usa) suzuki recommends the use of suzuki performance 4 motor oil or oils that meet api service classifications sf or sg and that have a viscosity rating of sae 10w-40. If engine oil with a rating of sae 10w-40 is not available, select an alter- native accordin...

  • Page 12: Information Labels

    1-6 general information information labels * e-28: fuel caution label enclosed. E : english f : french a: attached no. Label or plate name applied specification e-19 e-28 e-33 1 certification plate e a a 2 information label e a 3 gearshift pattern label e a 4 gearshift pattern label e / f a 5 tire a...

  • Page 13: Specifications

    General information 1-7 specifications dimensions and dry mass overall length ...................................................... 1 720 mm (67.7 in) overall width ....................................................... 1 070 mm (42.1 in) overall height ...............................................

  • Page 14: Partshark.Com

    1-8 general information chassis front suspension ................................................. Independent, double wishbone, coil spring, oil damped rear suspension .................................................. Swingarm type, coil spring, oil damped front wheel travel .........................

  • Page 15: Country And Area Codes

    General information 1-9 country and area codes the following codes stand for the applicable countries and areas: code country or area e-19 e-28 e-33 eu canada usa and california partshark.Com 877-999-5686.

  • Page 16: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 17: Periodic Maintenance

    2 6 periodic maintenance 2-1 contents periodic maintenance periodic maintenance schedule .......................................................2- 2 periodic maintenance chart .....................................................2- 2 maintenance and tune-up procedures ..................................

  • Page 18: Partshark.Com

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Note: more frequent servicing may be performed on vehicles that are use under sev...

  • Page 19: Partshark.Com

    Periodic maintenance 2-3 maintenance and tune-up procedures this section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Air cleaner if the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output a...

  • Page 20: Partshark.Com

    2-4 periodic maintenance fill a wash pan of a proper size with a non-flammable clean- ing solvent. Immerse the air cleaner element in the cleaning solvent and wash it. Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element, or it...

  • Page 21: Partshark.Com

    Periodic maintenance 2-5 exhaust pipe nuts and muffler bolts tighten the exhaust pipe nuts 1 and muffler mounting bolts/ nuts 2 . Remove the right footrest mud guard. ( ! 7-7) tighten the muffler connecting bolt 3 . # exhaust pipe nut: 23 n•m (2.3 kgf-m, 16.5 lb-ft) muffler connecting bolt: 23 n•m (...

  • Page 22: Partshark.Com

    2-6 periodic maintenance remove the valve inspection caps 3 . Note: valve clearance is to be checked when the engine is cold. The intake and exhaust valves must be checked and adjusted when the piston is at top-dead-center (tdc) on the compres- sion stroke. Turn the crankshaft until the tdc line 4 o...

  • Page 23: Partshark.Com

    Periodic maintenance 2-7 apply grease to new o-rings and install them to the valve inspection caps. & 09900-25030: suzuki super grease a ( usa) 09900-25010: suzuki super grease a ( others) tighten the valve inspection caps. Spark plug spark plug removal disconnect the spark plug cap 1 and remove the...

  • Page 24: Partshark.Com

    2-8 periodic maintenance spark plug gap measure the spark plug gap using the thickness gauge. If the spark plug gap is out of specification, adjust the gap. % standard spark plug gap: 0.6 0.7 mm (0.024 0.028 in) $ 09900-20803: thickness gauge or 09900-20804: thickness gauge electrode check the condi...

  • Page 25: Partshark.Com

    Periodic maintenance 2-9 throttle cable play adjust the throttle cable play a as follows: loosen the locknut 1 of the throttle cable. Turn the adjuster 2 in or out to obtain the correct play. % throttle cable play a : 3 5 mm (0.12 0.20 in) after adjusting the throttle cable play, tighten the locknut...

  • Page 26: Partshark.Com

    2-10 periodic maintenance engine oil and oil filter the oil should be changed while the engine is warm. Oil filter replacement should be done together with the engine oil change at the intervals shown above. Engine oil replacement place an oil pan under the engine oil drain plug 1 , and then drain o...

  • Page 27: Partshark.Com

    Periodic maintenance 2-11 apply engine oil lightly to new o-rings a and b before install- ing the oil filter cap. Install the new o-ring a onto the oil filter fitting boss of the clutch cover. Install the new o-ring b to the groove of the oil filter cap. Install new oil filter 2 . Install the spring...

  • Page 28: Partshark.Com

    2-12 periodic maintenance place an oil pan under the final gear case, and then drain oil by removing the drain plug 2 and filler plug 3 . Tighten the drain plug 2 . Remove the oil level check plug 4 and pour the specified oil through the filler hole until the oil over flows from the oil level check ...

  • Page 29: Partshark.Com

    Periodic maintenance 2-13 clutch remove the clutch adjuster cap 1 . Note: adjust the clutch release, when the engine is cold. Loosen the locknut 2 . Tighten the adjusting screw 3 until it stops. Loosen the adjusting screw 3 1/16 1 /8 turn. Tighten the locknut 2 to the specified torque while holding ...

  • Page 30: Partshark.Com

    2-14 periodic maintenance brakes brake pads remove the front wheels. ( ! 7-11) the extent of brake pad wear can be checked by observing the limit line 1 on the side of brake pads. When the wear reaches the limit line, replace the pads with new ones. ( ! 7-19) " brake shoes this vehicle is equipped w...

  • Page 31: Partshark.Com

    Periodic maintenance 2-15 rear brake lever (minor brake adjustment) after adjusting the brake pedal, check the rear brake lever play. The brake lever play b as measured at the lever holder should be between 3 5 mm (0.1 0.2 in) when the lever is lightly pulled in towards the grip. If adjustment is ne...

  • Page 32: Partshark.Com

    2-16 periodic maintenance air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper. The presence of air is...

  • Page 33: Partshark.Com

    Periodic maintenance 2-17 brake hose check the brake hoses for leakage, cracks, wear and dam- age. If any damages are found, replace the brake hoses with new ones. Tires tire tread condition operating the vehicle with excessively worn tires will decrease riding stability and consequently cause a dan...

  • Page 34: Partshark.Com

    2-18 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Vehicle load ...

  • Page 35: Partshark.Com

    Periodic maintenance 2-19 steering steering system should be adjusted properly for smooth han- dling of the handlebars and safe running. Toe-in place the vehicle on level ground. Make sure the tire pressure for right and left tires is same and set to the proper specification. Set the front wheels in...

  • Page 36: Partshark.Com

    2-20 periodic maintenance chassis bolts and nuts check that all chassis nuts and bolts are tightened to their specified torque. (refer to page 2-21 and 2-22 for the locations of the following nuts and bolts.) tighten initially at 1 month and every 3 months there- after. Item n•m kgf-m lb-ft 1 handle...

  • Page 37: Partshark.Com

    Periodic maintenance 2-21 partshark.Com 877-999-5686.

  • Page 38: Partshark.Com

    2-22 periodic maintenance partshark.Com 877-999-5686.

  • Page 39: Partshark.Com

    Periodic maintenance 2-23 general lubrication proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. 1 brake lever holder 5 brake cam &) grease 2 throttle lever and cable 6 brake cable *) motor oil 3 steer...

  • Page 40: Compression Pressure Check

    2-24 periodic maintenance compression pressure check the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership shoud i...

  • Page 41: Oil Pressure Check

    Periodic maintenance 2-25 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. % oil pressure: low or high oil pressure can indicate any of the following conditions: low oil pressure * clogged oil filter * oil leakage f...

  • Page 42: Partshark.Com

    2-26 periodic maintenance initial engagement and clutch lock-up inspection the lt-z250 is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies, it is essential that the clutches engage smoothly and gradually. Before checking the initi...

  • Page 43: Engine

    Engine 3-1 engine contents 3 engine components removable with engine in place............ 3- 2 engine removal and installation .................................................. 3- 3 engine removal................................................................................ 3- 3 engine installati...

  • Page 44: Partshark.Com

    3-2 engine engine components removable with engine in place the parts listed below can be removed and installed without removing the engine from the frame. Refer to the page listed in each section for removal and installation instructions. Engine left side engine right side engine center parts remov...

  • Page 45: Partshark.Com

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. Drain engine oil. ( ! 2-10) remove the...

  • Page 46: Partshark.Com

    3-4 engine turn the fuel valve to the on position. Disconnect the fuel and vacuum hoses. Remove the carburetor. ( ! 5-7) disconnect the engine ground lead wire 5 . Disconnect the neutral switch lead wire coupler 6 , signal generator lead wire coupler 7 and generator lead wire cou- pler 8 . Remove th...

  • Page 47: Partshark.Com

    Engine 3-5 remove the gearshift lever link 0 . Remove the reverse lock release cable a . Disconnect the spark plug cap. Remove the right footrest b . Remove the brake pedal c . Partshark.Com 877-999-5686.

  • Page 48: Partshark.Com

    3-6 engine loosen the muffler connecting bolt. Remove the exhaust pipe and gasket. Disconnect the breather hose d . Remove the starter motor lead wire. Remove the rear upper engine mounting nut, bolts and bracket e . Partshark.Com 877-999-5686.

  • Page 49: Partshark.Com

    Engine 3-7 remove the front and rear lower engine mounting nuts and bolts. Disengage the secondary driven gear shaft from the universal joint. Remove the right front fender bracket f . Dismount the engine to the right side. Partshark.Com 877-999-5686.

  • Page 50: Partshark.Com

    3-8 engine engine installation remount the engine in the reverse order of engine removal. Pay attention to the following points: note: * the engine mounting nuts are self-locking. * once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the speci...

  • Page 51: Partshark.Com

    Engine 3-9 check that the gearshift lever plays a , up and down, are same. If not, set the clutch release outer guide in suitable position. Fix the clutch release outer guide by tightening the clutch release outer guide nuts 1 . Loosen the locknut 2 . Tighten the adjusting screw 3 until it stops. Lo...

  • Page 52: Partshark.Com

    3-10 engine install a new exhaust pipe/muffler connector 4 into the muf- fler lip. Note: exhaust gas sealer should be applied to both of the inside and outside of the connector 4 . Exhaust gas sealer: permatex 1372 apply suzuki super grease to the o-rings. # 99000-25030: suzuki super grease a ( usa)...

  • Page 53: Partshark.Com

    Engine 3-11 install the reverse gearshift arm. % reverse gearshift arm angle b : 20 install the gearshift lever. % gearshift arm angle c : 35 adjust the gearshift lever height d . % gearshift lever height d d d d : 0 10 mm (0 0 .4 in) position the carburetor clamps as shown in the illustration. Afte...

  • Page 54: Engine Disassembly

    3-12 engine engine disassembly engine top side spark plug remove the spark plug. & 09930-10121: spark plug wrench set starter motor remove the starter motor. Remove the valve timing inspection plug 1 and generator cover cap 2 . Turn the crankshaft until the tdc line a on the generator rotor aligns w...

  • Page 55: Partshark.Com

    Engine 3-13 cam chain tension adjuster remove the spring holder bolt 1 , pin and spring. Remove the cam chain tension adjuster. Cylinder head cover remove the cylinder head cover. Camshaft remove the camshaft end cap 1 . Flatten the lock washer and remove the camshaft sprocket bolts. Remove the dowe...

  • Page 56: Partshark.Com

    3-14 engine remove the c-ring 5 . ' cylinder head remove the cylinder head nuts (m6) 1 . Loosen the cylinder base nuts (m6) 2 . Remove the cylinder head nuts (m8) diagonally. Remove the cylinder head. Note: if the cylinder head does not come off, lightly tap on the finless portion of it with a plast...

  • Page 57: Partshark.Com

    Engine 3-15 engine bottom side neutral switch remove the neutral switch 1 . Remove the switch contacts 2 and springs. Secondary driven bevel gear remove the secondary driven bevel gear cover. Remove the dowell pins and secondary driven bevel gear assembly 1 . Generator cover remove the generator cov...

  • Page 58: Partshark.Com

    3-16 engine oil filter remove the oil filter cover. Remove the oil filter and o-ring 1 . Clutch cover remove the clutch cover. Remove the dowel pins and gasket. Remove the clutch release ball assembly 1 , inner ball guide 2 , washer 3 and clutch release arm 4 . Clutch note: slightly loosen the clutc...

  • Page 59: Partshark.Com

    Engine 3-17 remove the clutch wheel assembly 1 . Remove the clutch bolts. Remove the clutch release plate 1 and springs. Using a chisel, unlock the nut. Remove the clutch sleeve hub nut with the special tool. & 09920-53730: clutch sleeve hub holder remove the washer 2 and primary driven gear assembl...

  • Page 60: Partshark.Com

    3-18 engine gearshift remove the gearshift arm 1 . Remove the shift cam shaft assembly 2 . Remove the gearshift cam plate 3 and stopper 4 . Oil pump drive gear remove the oil pump drive gear 1 and pin 2 . Oil pump remove the e-ring. Remove the oil pump driven gear 1 . Partshark.Com 877-999-5686.

  • Page 61: Partshark.Com

    Engine 3-19 remove the pin 2 and washer 3 . Remove the oil pump. Generator remove the generator rotor nut with the special tool. & 09930-44520: rotor holder install the special tool to the crankshaft end. & 09930-31921: rotor remover attachment remove the generator rotor with the special tool. & 099...

  • Page 62: Partshark.Com

    3-20 engine cam chain remove the cam chain. Crankcase remove the left crankcase bolts. Remove the right crankcase bolts. Separate the crankcase with the special tool. Note: * the crankcase separator arms should be parallel with the end face of the crankcase. * the crankshaft must remain in the left ...

  • Page 63: Partshark.Com

    Engine 3-21 drive train/gearshift cam remove the reverse idle gear assembly 1 . Remove the gearshift cam 2 remove the shafts 3 and forks 4 . Remove the shift cam lock shaft 5 . Remove the washers, reverse driven gear 6 and reverse dog 7 . Crankshaft remove the crankshaft with the special tool. & 099...

  • Page 64: Partshark.Com

    3-22 engine drive bevel gear using a chisel, unlock the nut. Fit the special tool onto the driveshaft. & 09930-73150: output shaft holder loosen the secondary drive bevel gear and nut by holding the special tool with a vise. Remove the secondary drive bevel gear and driveshaft assembly, countershaft...

  • Page 65: Partshark.Com

    Engine 3-23 engine components inspection and service cylinder head cover disassembly ' remove the valve inspection caps 1 . Remove the rocker arm shaft bolts 2 . Remove the rocker arm shafts 3 . Remove the rocker arms 4 and wave washers 5 . Cylinder head cover distortion after removing sealant from ...

  • Page 66: Partshark.Com

    3-24 engine rocker arm i.D. When checking the rocker arm, the inside diameter of the rocker arm and wear of the camshaft contacting surface should be checked. % rocker arm i.D. Standard: 12.000 1 2.018 mm (0.4724 0 .4731 in) & 09900-20605: dial calipers reassembly reassemble the cylinder head cover ...

  • Page 67: Partshark.Com

    Engine 3-25 cylinder head disassembly remove the intake pipe 1 . Remove the cam chain tensioner 2 . Cam chain tentioner inspection ( ! 3-34) compress the valve spring and remove the valve cotters from the valve stem with the special tools. & 09916-14510: valve spring compressor 09916-14910: attachme...

  • Page 68: Partshark.Com

    3-26 engine valve stem runout support the valve with the v-blocks and measure the valve stem runout with the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one. % valve stem runout service limit: 0.05 mm (0.002 in) & 09900-20701: magnetic stand 09900-2060...

  • Page 69: Partshark.Com

    Engine 3-27 valve stem wear measure the valve stem outside diameter with the micrometer. If the outside diameter is not within the specified value, replace the valve with a new one. If the valve stem outside diameter is within specification, but the valve stem deflection is not, replace the valve gu...

  • Page 70: Partshark.Com

    3-28 engine after fitting all valve guides, re-finish their guiding bores with the valve guide reamer. Be sure to clean and oil the guide after reaming. & 09916-34550: valve guide reamer (5.5 mm) 09916-34542: reamer handle note: insert the reamer from the combustion chamber and always turn the reame...

  • Page 71: Partshark.Com

    Engine 3-29 when installing the solid pilot, rotate it slightly. Seat the pilot snugly. Install the 45 cutter, attachment and t-handle. Initial seat cut descale and clean up the seat with the 45 cutter. Rotate the cutter one or two turns. Measure the valve seat width w after every cut. If the valve ...

  • Page 72: Partshark.Com

    3-30 engine final seat cut if the contact area w is too low or too narrow, use the 45 cut- ter to raise and widen the contact area. Note: after cutting the 15 angle, it is possible that the valve seat (45 ) is too narrow. If so, re-cut the valve seat to the correct width. After the desired seat posi...

  • Page 73: Partshark.Com

    Engine 3-31 valve spring the force of the coil spring keeps the valve seat tight. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also...

  • Page 74: Partshark.Com

    3-32 engine put on the valve spring retainer, and using the valve lifter, press down the springs, fit the cotter halves to the stem end, and release the lifter to allow the cotter 1 to wedge in between retainer and stem. Be sure that the rounded lip 2 of the cotter fits snugly into the groove 3 in t...

  • Page 75: Partshark.Com

    Engine 3-33 camshaft the camshaft should be checked for wear and also for runout of cams and journals if the engine has been noted to produce abnormal noise or vibration or to lack output power. Any of these malconditions could be caused by a worn camshaft. Camshaft cam wear worn-down cams are often...

  • Page 76: Partshark.Com

    3-34 engine if the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. % camshaft journal o.D. Standard: 21.959 21.976 mm (0.8645 0 .8652 in) & 09900-20205: micromet...

  • Page 77: Partshark.Com

    Engine 3-35 cylinder cylinder distortion check the gasket surface of the cylinder for distortion with a straightedge and the thickness gauge, taking a clearance read- ing at several places as indicated. If any clearance reading exceeds the service limit, replace the cylinder with a new one. % cylind...

  • Page 78: Partshark.Com

    3-36 engine piston ring to groove clearance measure the side clearances of the 1st and 2nd piston rings with the thickness gauge. If any clearance reading exceeds the ser- vice limit, replace both the piston and piston rings. % piston ring to groove clearance service limit (1st) : 0.18 mm (0.0071 in...

  • Page 79: Partshark.Com

    Engine 3-37 oversize piston ring the following oversize piston rings are used. They bear the fol- lowing identification numbers. Oversize oil ring the following oversize oil ring is available as optional parts. They bear the following identification mark. Oversize side rail just measure outside diam...

  • Page 80: Partshark.Com

    3-38 engine conrod and crankshaft conrod small end i.D. Measure the conrod small end inside diameter with the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. % conrod small end i.D. Service limit: 16.040 mm (0.6315 in) & 09900-2...

  • Page 81: Partshark.Com

    Engine 3-39 clutch clutch drive plates note: wipe off engine oil from the clutch drive plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one. % drive plate thickness standard: 2.7 2.9 mm...

  • Page 82: Partshark.Com

    3-40 engine clutch shoes inspect the clutch shoes for chips, cracks, uneven wear, and heat discoloration. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set. Note: the clutch shoes must always be changed as a set. One-...

  • Page 83: Partshark.Com

    Engine 3-41 apply thread lock super to the bolts, and then tighten them to the specified torque with a offset wrench. " starter clutch bolt: 26 n•m (2.6 kgf-m, 19.0 lb-ft) * 99000-32030: thread lock super 1303 & 09930-44520: rotor holder install the starter driven gear to the starter clutch. Check t...

  • Page 84: Partshark.Com

    3-42 engine transmission disassembly insert the special tool between the 2nd drive gear and 4th drive gear. Remove the 2nd drive gear by a hydraulic press. & 09950-81910: remover disassemble the transmission as shown. 1 reverse driven gear 2 reverse gear dog 3 1st driven gear 4 5th driven gear 5 3rd...

  • Page 85: Partshark.Com

    Engine 3-43 reassembly assemble the transfer in the reverse order of disassembly. Pay attention to the following points: note: * always use new snap rings. * before installing the gears, coat lightly engine oil to the shafts and gears. ' when installing a new snap ring, pay attention to the directio...

  • Page 86: Partshark.Com

    3-44 engine when installing the bushings, align the shaft hole with the bushing hole. Partshark.Com 877-999-5686.

  • Page 87: Partshark.Com

    Engine 3-45 gearshift fork shift fork to groove clearance clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting process. Measure the gearshift fork clearance in the groove of its respec- tive gear with the thickness gauge. If the clearance excee...

  • Page 88: Partshark.Com

    3-46 engine clutch cover disassembly remove the clutch release outer guide 1 . Remove the bearing with the special tool. & 09921-20240: bearing remover set note: if there is no abnormal noise, the bearing removal is not neces- sary. Inspection rotate the balls by hand to inspect for an abnormal nois...

  • Page 89: Partshark.Com

    Engine 3-47 crankcase bearing inspection rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is any- thing unusual. Bearing removal remove the bearing retainer...

  • Page 90: Partshark.Com

    3-48 engine bearing installation install the bearings with the special tool. & 09913-70210: bearing installer set install the bearing retainers. Note: when installing the bearing retainers, apply a small quantity of thread lock to the screws. $ 09900-32050: thread lock 1342 oil seal removal and inst...

  • Page 91: Partshark.Com

    Engine 3-49 apply suzuki super grease to the oil seal. # 99000-25030: suzuki super grease a ( usa) 99000-25010: suzuki super grease a ( others) note: when installing the oil seal, the stamped mark on the oil seal must face outside. Install the oil seal with the special tool. & 09913-70210: bearing i...

  • Page 92: Partshark.Com

    3-50 engine crankshaft disassembly reassembly determine the width between the webs referring to the figure when rebuilding the crankshaft. % crank web to web width standard: 53.0 – 0.1mm (2.087 – 0.004 in) 1 crankshaft (r) 2 crank pin 3 bearing 4 conrod 5 crankshaft (l) partshark.Com 877-999-5686.

  • Page 93: Partshark.Com

    Engine 3-51 drive train secondary bevel gears construction 1 bearing 2 shim 3 secondary bevel drive gear 4 washer 5 washer 6 secondary bevel driven gear 7 shim 8 bearing 9 secondary bevel gear shaft 0 bearing a oil seal b o-ring c water proof cover d snap ring item n•m kgf-m lb-ft a , b 100 10.0 72....

  • Page 94: Partshark.Com

    3-52 engine secondary driven bevel gear removal the following components must be removed in the described order before removing the secondary driven bevel gear. Note: refer to the following pages for the details of each step. Remove the rear wheel. ( ! 7-11) remove the swingarm. ( ! 7-56) remove the...

  • Page 95: Partshark.Com

    Engine 3-53 inspection inspect the removed parts for the following abnormalities. * drive and driven bevel gears damage or wear * improper tooth contact * abnormal noise of bearings * bearing damage or wear * oil seal damage or wear secondary driven bevel gear reassembly install the bearing. Note: p...

  • Page 96: Partshark.Com

    3-54 engine apply 4 5 gram of water resistance grease to the outside of the seal lip groove. Apply suzuki super grease to the seal lip groove and install it. + 99000-25160: water resistance grease # 99000-25030: suzuki super grease a ( usa) 99000-25010: suzuki super grease a (others) apply suzuki su...

  • Page 97: Partshark.Com

    Engine 3-55 secondary gear shims adjustment remove the secondary bevel gear cover. Hold the bearings with the special tool. & 09921-21910: bearing holder set a dial gauge on the driven bevel gear as shown. Measure the backlash by turning the driven bevel gear shaft in each direction, reading the tot...

  • Page 98: Partshark.Com

    3-56 engine tooth contact after backlash adjustment is carried out, the tooth contact must be checked. Pay attention to the following procedures: remove the driven bevel gear. Clean and degrease several teeth of the drive and driven bevel gears. Apply a coating of machinist s layout dye or paste to ...

  • Page 99: Partshark.Com

    Engine 3-57 part no. Shim thickness for drive bevel gear ( : 3-58) 24935-19b00-025: 0.25 mm (0.0098 in) 24935-19b00-030: 0.30 mm (0.0118 in) 24935-19b00-035: 0.35 mm (0.0138 in) 24935-19b00-115 0.30+0.30=0.60 mm (0.0236 in) 0.30+0.35=0.65 mm (0.0256 in) 0.35+0.35=0.70 mm (0.0276 in) 0.25+0.25+0.25=0...

  • Page 100: Partshark.Com

    3-58 engine reassembly information item n•m kgf-m lb-ft 12 100 10.0 72.5 @ part no. Shim thickness list of shims a available for the drive bevel gear side 24935-19b00-025: 0.25 mm (0.0098 in) 24935-19b00-030: 0.30 mm (0.0118 in) 24935-19b00-035: 0.35 mm (0.0138 in) 24935-19b00-115 0.30+0.30=0.60 mm ...

  • Page 101: Engine Reassembly

    Engine 3-59 engine reassembly reassemble the engine in the reverse order of disassembly. Pay special attention to the following points: note: apply engine oil to each running and sliding part before reas- sembling. Engine bottom side drive train install the driveshaft and countershaft assembly. Driv...

  • Page 102: Partshark.Com

    3-60 engine crankshaft when mounting the crankshaft in the crankcase, it is neces- sary to pull its left end into the crankcase with the special tool. Note: use proper bars. & 09910-32812: crankshaft installer install the reverse dog and washer 1 . Install the reverse driven gear and washer 2 . Reas...

  • Page 103: Partshark.Com

    Engine 3-61 install the gearshift cam. Install the gearshift forks and shafts as shown. Note: each fork differs in shape. 1 for reverse/1st gear 2 for 2nd/3rd gear 3 for 4th/5th gear install the reverse idle gear shaft 4 . Install the snap ring 5 , washer 6 and spacer 7 . Install the reverse idle ge...

  • Page 104: Partshark.Com

    3-62 engine install the oil sump filter as its projection a faces upward. Crankcase wipe the crankcase mating surfaces (both surfaces) with a cleaning solvent. Fit the dowel pins onto the left half on the crankcase. Apply engine oil to the conrod big end and gears. Apply suzuki bond to the mating su...

  • Page 105: Partshark.Com

    Engine 3-63 assemble the crankcase within a few minutes. Note: fit the clamp to the bolt a . " crankcase bolt: 11 n•m (1.1 kgf-m, 8.0 lb-ft) cam chain install the cam chain. Generator install the starter driven gear 1 . Install the key 2 . Note: degrease the tapered portion of the generator rotor as...

  • Page 106: Partshark.Com

    3-64 engine oil pump install the oil pump. Install the washer 1 and pin 2 . Install the oil pump driven gear and e-ring. Oil pump drive gear install the pin 1 . Install the oil pump drive gear. Note: flange side of the gear is positioned inside. Gearshift install the spring 1 , washer 2 and gearshif...

  • Page 107: Partshark.Com

    Engine 3-65 apply thread lock to the gearshift cam bolt and install the gearshift cam plate guide. $ 99000-32050: thread lock 1342 install the gearshift cam shaft assembly so that the stopper 5 comes between the spring ends 6 . Install the washer 7 and gearshift arm. Clutch apply engine oil to each ...

  • Page 108: Partshark.Com

    3-66 engine install the clutch pressure plate 2 . Align the clutch drive plates in line to facilitate later assembly. Install the washer 3 onto the countershaft. Install the primary driven gear assembly. Install the washer 4 . Install the clutch sleeve hub assembly into the primary driven gear assem...

  • Page 109: Partshark.Com

    Engine 3-67 tighten the clutch sleeve hub nut to the specified torque with the special tool. " clutch sleeve hub nut: 100 n•m (10.0 kgf-m, 72.5 lb-ft) & 09920-53730: clutch sleeve hub holder stake the clutch sleeve hub nut with a center punch. Install the clutch springs and clutch release plate. Tig...

  • Page 110: Partshark.Com

    3-68 engine install the clutch shoes. Install the washer as its convex side faces outside. Before installing the clutch shoe nut, apply engine oil to the thread and inside surface of the nut. While holding the generator rotor with the special tool, tighten the clutch shoe nut to the specified torque...

  • Page 111: Partshark.Com

    Engine 3-69 oil filter before installing the oil filter, fit new o-rings and apply engine oil lightly to them. Install the spring 1 and oil filter 2 . ' starter idle gear install the idle driven gear 1 , shaft 2 and spacer 3 . Generator cover install the dowel pins and new gasket. Install the revers...

  • Page 112: Partshark.Com

    3-70 engine apply suzuki bond to the mating surface of the secondary bevel gear cover. , 99104-31140: suzuki bond 1207b (usa) - 99000-31110: suzuki bond 1215 (others) install the secondary bevel gear cover. Neutral switch install the springs and switch contacts. Fit new o-ring and install the neutra...

  • Page 113: Partshark.Com

    Engine 3-71 install the 2nd ring 3 and the 1st ring 4 . Note: 1st ring and 2nd ring differ in shape. 1st ring has letter r marked on the side. Be sure to bring the marked side to the top when fitting it to the piston. Position the gaps of the three rings as shown. Before inserting the piston into th...

  • Page 114: Partshark.Com

    3-72 engine cylinder fit the dowel pins and new gasket 1 . ' note: * the dowel pins are identified by their length. * shorter ones a are for cylinder base. * apply engine oil to the piston ring grooves and cylinder wall. Hold each piston ring with proper position, insert the piston into the cylinder...

  • Page 115: Partshark.Com

    Engine 3-73 install the cylinder head. Install the washers and cylinder head nuts (m8) as shown. Tighten the cylinder head nuts (m8) diagonally to the speci- fied torque. " cylinder head nut (m8): 23 n•m (2.3 kgf-m, 16.5 lb-ft) tighten the cylinder base nuts (m6) 3 and head nuts (m6) 4 to the specif...

  • Page 116: Partshark.Com

    3-74 engine install the camshaft and camshaft sprocket. Engage the hole of the sprocket c with the locating pin on the camshaft as shown. Align the lines d on the camshaft so that they are parallel with the surface of the cylinder head. Note: * do not rotate the generator while doing this. When the ...

  • Page 117: Partshark.Com

    Engine 3-75 turn the crankshaft until the tdc line e on the generator rotor aligns with the index mark f on the crankcase. Cylinder head cover clean the mating surface of the cylinder head and head cover before matching. Install the dowel pins to the cylinder head. Apply suzuki bond to the periphery...

  • Page 118: Partshark.Com

    3-76 engine install new gasket 3 and cam chain tension adjuster to the cylinder block and tighten its mounting bolts to the specified torque. " cam chain tension adjuster bolt: 10 n•m (1.0 kgf-m, 7.0 lb-ft) install new o-ring 4 . Install the spring and pin 5 . Tighten the spring holder bolt 6 to the...

  • Page 119: Drive Train

    2 4 6 drive train 4-1 contents drive train rear driving system ...............................................................................4- 2 rear drive removal .......................................................................4- 3 rear drive disassembly ......................................

  • Page 120: Rear Driving System

    4-2 drive train rear driving system 1 final gear case cover 2 shim, lh 3 bevel ring gear 4 shim, rh 5 final gear case 6 shim 7 bevel pinion gear 8 pinion gear shaft coupling joint 9 propeller shaft 0 universal joint fwd partshark.Com 877-999-5686.

  • Page 121: Partshark.Com

    Drive train 4-3 rear drive removal remove the final gear case under cover 1 . Drain gear oil. ( ! 2-11) remove the rear wheels. ( ! 7-11) remove the rear wheel hubs. ( ! 7-11) remove the rear brake 2 . ( ! 7-46) remove the axle housing set bolts/nuts. Remove the final gear case together with the pro...

  • Page 122: Partshark.Com

    4-4 drive train remove the rear axle together with the axle housing. Remove the o-ring 4 . Rear drive disassembly final gear case remove the final gear case cover bolts diagonally and evenly. Pry the cover at the arrows as shown by tapping with a plastic mallet. Remove the ring gear and shims. Remov...

  • Page 123: Partshark.Com

    Drive train 4-5 remove the snap ring. Remove the o-ring 1 . Drive out the bearing from the other side with the special tool. " 09913-70210: bearing installer set note: if there is no abnormal condition, the bearing removal is not nec- essary. # remove the bearing and oil seal with a suitable tool. N...

  • Page 124: Partshark.Com

    4-6 drive train remove the bearing with the special tool. " 09913-70210: bearing installer set note: if there is no abnormal condition, the bearing removal is not nec- essary. # remove the pinion gear shaft coupling joint with the special tools. " 09923-74510: bearing remover 09930-30104: sliding sh...

  • Page 125: Partshark.Com

    Drive train 4-7 remove the pinion gear assembly and shim. Remove the stopper ring 1 and o-ring 2 . Remove the bearing with a commercially available bearing puller or a hydraulic press. Note: if there is no abnormal condition, the bearing removal is not nec- essary. # remove the pinion gear pilot bea...

  • Page 126: Partshark.Com

    4-8 drive train universal joint remove the c-rings from the universal joint. # remove the bearings by tapping with the special tool and a hammer. " 09913-70210: bearing installer set remove the universal joint. Replace the removed c-rings with new ones. Partshark.Com 877-999-5686.

  • Page 127: Partshark.Com

    Drive train 4-9 rear drive inspection propeller shaft inspect the splines of the propeller shaft for wear or damage. Also, inspect the boot for cuts or damage. If any defects are found, replace the propeller shaft and its boot with new ones. Universal joint inspect the universal joint and outer surf...

  • Page 128: Partshark.Com

    4-10 drive train check the outer race play and smooth rotation of the bearing by hand while it is on the pinion gear shaft. Inspect the pinion gear for wear or damage. If the pinion gear is damaged, inspect the ring gear also. If any defects are found, replace the bearing and gear with the new ones....

  • Page 129: Partshark.Com

    Drive train 4-11 rear axle inspect the splines of the rear axle and splines of the ring gear for wear or damage. If any wear or damage is found, replace the rear axle and ring gear with the new ones. Check the axle shaft runout. ( ! 7-61) rear drive reassembly reassemble the rear drive in the revers...

  • Page 130: Partshark.Com

    4-12 drive train final gear case bearing drive the bearings into the gear case and case cover with the special tool. " 09913-70210: bearing installer set dust seal fix the bearing race with the snap ring. Apply suzuki super grease to the bearing. $ 99000-25030: suzuki super grease a ( usa) 99000-250...

  • Page 131: Partshark.Com

    Drive train 4-13 bevel pinion gear shaft bearing drive the bearing onto the shaft with the special tool. " 09913-70210: bearing installer set bevel pinion gear/shim/locknut [final assembly] install new o-ring 1 onto the pinion gear shaft. Install the shim, pinion gear assembly and new bearing locknu...

  • Page 132: Partshark.Com

    4-14 drive train bevel pinion gear shaft oil seal install new stopper ring to pinion gear shaft securely. Install new oil seal to the gear case with the special tool. Apply suzuki super grease to the new oil seal lip groove. " 09913-85210: bearing/oil seal installer $ 99000-25030: suzuki super greas...

  • Page 133: Partshark.Com

    Drive train 4-15 final gear case cover/gear case [final assembly] coat new o-ring with suzuki super grease and apply suzuki bond to the mating surface of the cover, then install the gear case cover. $ 99000-25030: suzuki super grease a ( usa) 99000-25010: suzuki super grease a ( others) ' 99104-3114...

  • Page 134: Partshark.Com

    4-16 drive train install new c-rings by tapping with a copper hammer. After reassembling the universal joint, check the joint move- ment smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. Rear drive installation install the rear drive in the reverse o...

  • Page 135: Partshark.Com

    Drive train 4-17 install the spring into the rear end of the propeller shaft. Apply suzuki super grease to the splines of the propel- ler shaft. $ 99000-25030: suzuki super grease a ( usa) 99000-25010: suzuki super grease a ( others) tighten the axle housing set bolts/nuts 1 (rh) and 2 (lh) to the s...

  • Page 136: Partshark.Com

    4-18 drive train shim adjustment backlash install the pinion gear assembly, removed shim and new bearing locknut. ( ! 4-13) tighten the bearing locknut to the specified torque. ( ! 4-13) note: at this time, it is not necessary to stake the bearing locknut. ( ! 4-13) install the removed right side sh...

  • Page 137: Partshark.Com

    Drive train 4-19 install the final gear case cover and tighten its bolts to the specified torque in a crisscross pattern. ( ! 4-15) note: * it is not necessary to install the o-ring to the final gear case cover at this time. * do not apply thread lock super to the final gase cover bolts at this time...

  • Page 138: Partshark.Com

    4-20 drive train tooth contact after backlash adjustment and left shim selection are carried out, the tooth contact must be checked. Pay attention to the fol- lowing procedures: remove the ring gear. Clean and degrease several teeth on the ring gear and pinion gear, and then apply a coating of machi...

  • Page 139: Partshark.Com

    Drive train 4-21 reassembly information pinion gear shim right side of ring gear shim matching surfaces 26 n•m (2.6 kgf-m, 19.0 lb-ft) 26 n•m (2.6 kgf-m, 19.0 lb-ft) left side of ring gear shim 4 5 g ram 100 n.M (10.0 kgf-m, 72.5 lb-ft) partshark.Com 877-999-5686.

  • Page 140: Partshark.Com

    4-22 drive train 4 5 g ram partshark.Com 877-999-5686.

  • Page 141: Fuel System

    Fuel system 5-1 5 fuel system contents fuel tank ...................................................................................................5- 2 construction ....................................................................................5- 2 fuel line inspection ...........................

  • Page 142: Fuel Tank

    5-2 fuel system fuel tank construction 1 fuel tank 2 fuel cap 3 breather hose 4 gasket 5 seal washer 6 fuel valve 7 fuel hose partshark.Com 877-999-5686.

  • Page 143: Partshark.Com

    Fuel system 5-3 fuel line inspection inspect the fuel lines, fuel tank, fuel tank breather hoses and fuel tank cap for damage, clogging and leakage of fuel. If any dam- ages are found, replace the defective parts with the new ones. Removal remove the front fender. ( ! 7-6) turn the fuel valve to the...

  • Page 144: Fuel Valve

    5-4 fuel system fuel valve removal and inspection remove the fuel tank. ( ! 5-3) drain fuel completely. Remove the fuel valve. " fuel strainer if the fuel strainer is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel strainer with compressed...

  • Page 145: Carburetor

    Fuel system 5-5 carburetor construction 1 top cap 2 spring 3 holder 4 o-ring 5 spring 6 washer (t=0.5 mm, 0.02 in) 7 e-ring 8 spacer 9 washer (t=1.0 mm, 0.04 in) 0 jet needle a diaphragm b ring c piston valve d vacuum hose e air vent hose f side cover g o-ring h coasting enrichment valve i coasting ...

  • Page 146: Partshark.Com

    5-6 fuel system specifications e-19: eu e-28: canada e-33: usa (california) i.D. No. Location carburetor has an i.D. Number 1 printed on its body. Item specification e-19, 28 e-33 carburetor type mikuni bsr29 ← bore size 29.0 mm (1.14 in) ← i.D. No. 21g0 21g1 idle r/min 1 500 – 100 r/min ← float hei...

  • Page 147: Partshark.Com

    Fuel system 5-7 removal remove the seat. ( ! 7-5) disconnect the air vent hose 1 . Disconnect the fuel hose 2 and vacuum hose 3 . Disconnect the starter cable 4 . Loosen the carburetor clamp screws. Pull out the carburetor from between the engine and air cleaner. Remove the carburetor side cover 5 ....

  • Page 148: Partshark.Com

    5-8 fuel system disassembly remove the fuel hose 1 , overflow hose 2 , vacuum hose 3 and air vent hose 4 . Remove the throttle stop screw 5 . Remove the carburetor top cap. # remove the spring and diaphragm assembly 6 . Remove the jet needle holder. Do not use compressed air on the carburetor body b...

  • Page 149: Partshark.Com

    Fuel system 5-9 remove the following parts. 7 jet needle holder 8 o-ring 9 spring 0 washer (t=0.5 mm, 0.02 in) a jet needle b washer (t=1.0 mm, 0.04 in) remove the diaphragm by removing the ring c . Remove the coasting enrichment valve cover d and spring. Remove the coasting enrichment valve e . Rem...

  • Page 150: Partshark.Com

    5-10 fuel system remove the float chamber. Remove the o-ring g . # remove the float pin h , float i and needle valve j . Remove the valve seat k . Replace the removed o-ring with a new one to prevent leakage of fuel. Partshark.Com 877-999-5686.

  • Page 151: Partshark.Com

    Fuel system 5-11 remove the following parts. L main jet, main jet ring, needle jet holder and needle jet m pilot screw n starter jet o pilot jet note: before removing the pilot screw m , its setting must be deter- mined. Slowly turn the pilot screw clockwise and count the num- ber of turns until it ...

  • Page 152: Partshark.Com

    5-12 fuel system cleaning " clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner. If necessary, soak each cir- cu...

  • Page 153: Partshark.Com

    Fuel system 5-13 needle valve inspection if foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve ...

  • Page 154: Partshark.Com

    5-14 fuel system valve seat install the valve seat 1 into the carburetor body, and then tighten the screw 2 . Note: make sure that the collar of the screw 2 holds the step of the valve seat 1 securely. Diaphragm install the diaphragm to the piston valve with the lug on the diaphragm aligned with the...

  • Page 155: Partshark.Com

    Fuel system 5-15 remounting remount the carburetor assembly in the reverse order of removal. Pay attention to the following points: fit the lug on the carburetor with the intake pipe s projection. Position the carburetor clamps as shown in the illustration. Connect the carburetor hoses properly. ( !...

  • Page 156: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 157: Lubrication System

    6 lubrication system 6-1 contents lubrication system lubrication system ...............................................................................6- 2 engine lubrication circuit .........................................................6- 2 engine lubrication flow chart ............................

  • Page 158: Lubrication System

    6-2 lubrication system lubrication system engine lubrication circuit oil pump oil filter lubrication oil returned oil partshark.Com 877-999-5686.

  • Page 159: Partshark.Com

    Lubrication system 6-3 intake side lubrication oil returned oil exhaust side partshark.Com 877-999-5686.

  • Page 160: Partshark.Com

    6-4 lubrication system engine lubrication flow chart oil sump fil ter orifice orifice oil fil ter oil pump cylinder driveshaft right end bearing clutch release bearing crankshaft right end bearing driveshaft b ushings/ gears conr od big end bearing cylinder w all & pist on r ocker arms & shafts cams...

  • Page 161: Oil Pressure

    Lubrication system 6-5 oil pressure ( ! 2-25) oil filter ( ! 2-10) oil strainer ( ! 3-20, -61 and -62) oil pump ( ! 3-18 and -64) partshark.Com 877-999-5686.

  • Page 162: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 163: Chassis

    Chassis 7-1 chassis 7 contents exterior parts ........................................................................................7- 3 construction ....................................................................................7- 3 removal ......................................................

  • Page 164: Chassis

    7-2 chassis chassis contents rear brake ............................................................................................... 7-45 construction ................................................................................... 7-45 removal and disassembly.....................................

  • Page 165: Exterior Parts

    Chassis 7-3 exterior parts construction 1 front fender 2 fuel tank top cover 3 fuel tank side cover 4 front fender bracket 5 headlight case partshark.Com 877-999-5686.

  • Page 166: Partshark.Com

    7-4 chassis 1 rear fender 2 rear fender cover 3 footrest mud guard partshark.Com 877-999-5686.

  • Page 167: Partshark.Com

    Chassis 7-5 removal seat remove the seat by pulling the lever. Front grip bar remove the front grip bar 1 . Rear grip bar remove the rear grip bar 1 . Fuel tank side cover remove the seat. ( ! Above) remove the fuel tank side covers 1 and 2 . Partshark.Com 877-999-5686.

  • Page 168: Partshark.Com

    7-6 chassis front fender remove the fuel tank side covers. ( ! 7-5) remove the screws and fasteners. Open the fuel tank cap and remove the fuel tank top cover 1 . Remove the reverse lock release knob 2 . Remove the screws that connect the front fender with the head light. Remove the front fender. Pa...

  • Page 169: Partshark.Com

    Chassis 7-7 footrest mud guard remove the fuel tank side covers. ( ! 7-5) remove the footrest mud guards 1 and 2 . Footrest remove the footrest mud guards. ( ! Above) remove the footrest 1 and 2 . Rear fender remove the fuel tank side covers. ( ! 7-5) remove the battery holder 1 and battery. Partsha...

  • Page 170: Partshark.Com

    7-8 chassis remove the screws. Pull out the taillight assembly 2 with the bracket. Remove the rear fender mounting bolts. Remove the footrest mud guards. Remove the rear fender. Remounting remount the exterior parts in the reverse order of removal. Pay attention to the following points: front grip b...

  • Page 171: Partshark.Com

    Chassis 7-9 footrest apply thread lock to the bolts a and tighten each bolt to the specified torque. # 99000-32050: thread lock 1342 " footrest mounting bolt a : 55 n•m (5.5 kgf-m, 40.0 lb-ft) footrest mounting bolt b : 26 n•m (2.6 kgf-m, 19.0 lb-ft) partshark.Com 877-999-5686.

  • Page 172: Front And Rear Wheels

    7-10 chassis front and rear wheels construction 1 front brake disc 2 spacer 3 dust seal 4 bearing 5 spacer 6 front wheel hub 7 rear wheel hub 8 hub plate 9 disc cover item n•m kgf-m lb-ft a 23 2.3 16.5 b 50 5.0 36.0 c 65 6.5 47.0 d 138 13.8 99.9 @ partshark.Com 877-999-5686.

  • Page 173: Partshark.Com

    Chassis 7-11 removal front and rear wheels place the vehicle on the level ground. Support the vehicle with a jack or wooden block. Remove the wheel. Front wheel hub remove the front wheel. ( ! Above) remove the front hub plate 1 . Remove the cotter pin and loosen the wheel hub nut with applying the ...

  • Page 174: Partshark.Com

    7-12 chassis inspection and disassembly dust seal inspect the dust seal lips for wear or damage. If any damages are found, replace the dust seal with a new one. Remove the dust seals with the special tool. % 09913-50121: oil seal remover $ hub bearings inspect the inner race play of the hub bearing ...

  • Page 175: Partshark.Com

    Chassis 7-13 reassembly and remounting front wheel hub apply suzuki super grease to the hub bearings and the lips of the dust seals before installing them. & 99000-25030: suzuki super grease a ( usa) 99000-25010: suzuki super grease a ( others) install the hub bearings and spacer into the front whee...

  • Page 176: Partshark.Com

    7-14 chassis install the spacer 4 to the front wheel hub. Install the front wheel hub to the front axle 5 . Install the front brake caliper. ( ! 7-24) tighten the front wheel hub nut to the specified torque. " front wheel hub nut: 65 n•m (6.5 kgf-m, 47.0 lb-ft) install the cotter pin into the front ...

  • Page 177: Partshark.Com

    Chassis 7-15 install the rear wheel hub and washer. Note: the convex side of the washer faces outside. Tighten the rear wheel hub nut to the specified torque. " rear wheel hub nut: 138 n•m (13.8 kgf-m, 99.9 lb-ft) install the cotter pin into the rear axle as shown. Install the rear hub plate. (rh on...

  • Page 178: Tires

    7-16 chassis tires tire replacement remove the front and rear wheels. ( ! 7-11) after removing the air valve cap, release the tire pressure by depressing the valve. Dismount the bead from the rim completely as shown. Separate the tire from the rim by using a set of tire levers and rim protectors. $ ...

  • Page 179: Partshark.Com

    Chassis 7-17 when installing each tire, make sure the arrow a on the tire points in the direction of rotation. Also, make sure the outer side of the wheel rim is facing outward. Note: for inspecting the tire refer to page 2-17. Inspect the valve core, before installation. Inflate the tire to seat th...

  • Page 180: Front Brake

    7-18 chassis front brake construction ( $ * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. * do not use any brake fluid taken from old, used or unsealed containers. Never...

  • Page 181: Partshark.Com

    Chassis 7-19 brake pad replacement remove the front wheel. ( ! 7-11) remove the brake caliper mounting bolts 1 and brake pad mounting pins 2 . Remove the brake pads. $ install the new brake pads. Note: the shim must be installed to the caliper piston side pad. Tighten the brake pad mounting pins 3 a...

  • Page 182: Partshark.Com

    7-20 chassis connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle. Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. Close the air bleeder valve and disconnect the clear hose. Fill th...

  • Page 183: Partshark.Com

    Chassis 7-21 place a rag over the brake caliper piston to prevent the piston from popping out and then force out the piston using com- pressed air. $ remove the dust seal and piston seal. $ remove the cap 4 and loosen the brake caliper holder slide pin 5 . Remove the brake caliper holder 6 . Remove ...

  • Page 184: Partshark.Com

    7-22 chassis brake caliper piston inspect the brake caliper piston for any scratches or other dam- age. If any damages are found, replace the piston with a new one. Rubber parts inspect the rubber parts for damage. If any damages are found, replace them with new ones. Caliper holder inspect the cali...

  • Page 185: Partshark.Com

    Chassis 7-23 brake caliper reassembly and remounting reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: wash the caliper bore and piston with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal...

  • Page 186: Partshark.Com

    7-24 chassis apply suzuki silicone grease to the brake caliper holder slide pin. * 99000-25100: suzuki silicone grease install the pin 1 , washer 2 and caliper holder 3 to the cali- per. Apply thread lock super to the pin 1 . + 99000-32130: thread lock super 1360 tighten the pin 1 to the specified t...

  • Page 187: Partshark.Com

    Chassis 7-25 brake disc inspection remove the front wheel. ( ! 7-10) remove the caliper. ( ! 7-19) inspect the brake disc for cracks or damage and measure the thickness using the micrometer. If any damages are found or if the thickness is less than the service limit, replace the brake disc with a ne...

  • Page 188: Partshark.Com

    7-26 chassis master cylinder removal and disassembly place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any split brake fluid. Remove the brake hose union bolt and disconnect the brake hose. $ remove the master cylinder assembly. Disconnect the brake switch coupler. R...

  • Page 189: Partshark.Com

    Chassis 7-27 remove the piston/secondary cup, primary cup and spring. 7 secondary cup 8 piston 9 primary cup 0 spring master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. Piston ...

  • Page 190: Partshark.Com

    7-28 chassis align the master cylinder holder s mating surface 1 with the punched mark 2 on the handlebars and tighten the upper clamp bolt first. " master cylinder clamp bolt: 10 n•m (1.0 kgf-m, 7.0 lb-ft) a master cylinder b master cylinder upper clamp bolt c handlebar d clearance tighten the brak...

  • Page 191: Front Suspension

    Chassis 7-29 front suspension construction 1 front shock absorber 2 upper wishbone arm 3 bushing 4 lower wishbone arm 5 steering knuckle 6 snap ring 7 knuckle end a shock absorber mounting upper nut b shock absorber mounting lower nut c wishbone arm pivot nut d steering knuckle nut e tie rod end nut...

  • Page 192: Partshark.Com

    7-30 chassis removal and disassembly remove the wheel hub. ( ! 7-11) remove the brake hose clamp 1 . Disconnect the brake hose from the brake hose clamp 2 . Remove the front disc cover 3 . Remove the cotter pin, tie rod end nut and washer. Disconnect the tie rod end with a commercially available bal...

  • Page 193: Partshark.Com

    Chassis 7-31 remove the front shock absorber 7 . Remove the cotter pins, knuckle nuts and washers. Disconnect the steering knuckle 8 with a commercially avail- able ball bearing joint remover. Inspection front shock absorber inspect the shock absorber for oil leakage or damage. If any damages are fo...

  • Page 194: Partshark.Com

    7-32 chassis knuckle inspect the knuckle for damage. If any damages are found, replace the knuckle with a new one. Knuckle end inspect the knuckle end boots for wear or damage. If any dam- ages are found, replace the wishbone arm with a new one. Wishbone arm inspect the wishbone arms for wear or dam...

  • Page 195: Partshark.Com

    Chassis 7-33 reassembly and remounting reassemble and remount the front suspension in the reverse order of removal and disassembly. Pay attention to the following points: degrease the tapered portions of the knuckle, knuckle end and tie rod end with nonflammable cleaning solvent. Install the wishbon...

  • Page 196: Partshark.Com

    7-34 chassis apply thread lock super to the wishbone arm pivot bolts 3 . Tghten the upper and lower front shock absorber mounting nuts 2 and the wishbone arm pivot nuts 3 to the specified torque. , 99000-32030: thread lock super 1303 (usa) - 99000-32110: thread lock super 1322 (others) " wishbone ar...

  • Page 197: Steering

    Chassis 7-35 steering construction item n•m kgf-m lb-ft a 23 2.3 16.5 b 23 2.3 16.5 c 49 4.9 35.5 d 29 2.9 21.0 e 29 2.9 21.0 @ 1 steering head cover 2 handlebars 3 handlebar upper clamp 4 handlebar lower clamp 5 brake cable guide 6 steering shaft holder 7 steering shaft 8 dust seal 9 bushing 0 dust...

  • Page 198: Partshark.Com

    7-36 chassis removal remove the front fender. ( ! 7-6) remove the master cylinder assembly 1 from the handle- bars. ( ! 7-26) remove the throttle lever case 2 . Disconnect the rear brake cable 3 and remove the handlebar switch 4 . Disconnect the fuel vent hose and remove the steering head cover 5 . ...

  • Page 199: Partshark.Com

    Chassis 7-37 remove the tie rod ends with a commercially available ball bearing joint remover. Remove the cotter pin and steering shaft nut 9 , washer 0 and dust seal a . $ remove the o-ring b . Remove the steering shaft holder bolts. Remove the steering shaft holder half. Remove the steering shaft ...

  • Page 200: Partshark.Com

    7-38 chassis remove the steering shaft. Remove the dust seal f from the steering shaft. Inspection and disassembly inspect the removed parts for the following abnormalities. * handlebar distortion * handlebar clamp wear dust seals and o-ring inspect the dust seals and o-ring for wear or damage. If a...

  • Page 201: Partshark.Com

    Chassis 7-39 steering shaft inspect the steering shaft for distortion or bends. If any damages are found, replace the steering shaft with a new one. Steering shaft holder inspect the two steering shaft holders for wear or damage. If any damages are found, replace the steering shaft holders with new ...

  • Page 202: Partshark.Com

    7-40 chassis reassembly and remounting reassemble and remount the steering stem in the reverse order of removal and disassembly. Pay attention to the following points: steering shaft apply suzuki super grease to the o-ring, dust seals and steering shaft before remounting the steering shaft. & 99000-...

  • Page 203: Partshark.Com

    Chassis 7-41 tighten the steering shaft holder bolts to the specified torque. " steering shaft holder bolt: 23 n•m (2.3 kgf-m, 16.5 lb-ft) note: make sure that the wiring harness, cables and brake hose rout- ing are properly. ( ! 9-12 to -14) degrease the tapered portions of the tie rod ends with no...

  • Page 204: Partshark.Com

    7-42 chassis install the steering head cover with the projection a inserting into the cushion b on the steering head cover bracket. Note: the indicator light position on the steering head cover is shown on page 8-24. Install the handle switch with the lug 5 on the switch half inserted into the hole ...

  • Page 205: Partshark.Com

    Chassis 7-43 toe-in adjustment adjust the toe-in as follows: place the vehicle on level ground and set the handlebars straight. Make sure all the tires are inflated to the standard pressure. ( ! 2-18) place 75 kg (165 lbs) of weight on the seat. Loosen the locknuts ( 1 , 2 ) on each tie rod. $ measu...

  • Page 206: Partshark.Com

    7-44 chassis front wheel, front brake, front suspension and steering reassembling information item n•m kgf-m lb-ft 12 23 2.3 16.5 3 49 4.9 35.5 45 29 2.9 21.0 6 60 6.0 43.5 @ @ item n•m kgf-m lb-ft 7 60 6.0 43.5 8 65 6.5 47.0 9 29 2.9 21.0 0 50 5.0 36.0 a 65 6.5 47.0 b 23 2.3 16.5 bend the cotter pi...

  • Page 207: Rear Brake

    Chassis 7-45 rear brake construction item n•m kgf-m lb-ft a 60 6.0 43.5 b 11 1.1 8.0 c 11 1.1 8.0 @ 1 dust seal 8 brake camshaft a brake panel nut 2 drum cover 9 o-ring b brake cam lever nut 3 brake drum 0 brake lining indicator plate 4 brake shoe a o-ring 5 o-ring b brake panel 6 snap ring c brake ...

  • Page 208: Partshark.Com

    7-46 chassis removal and disassembly raise the rear wheel off the ground and support the vehicle with a jack or wooden block. Remove the right rear wheel hub. ( ! 7-11) disconnect the brake cables. Remove the drum cover bolts. Remove the drum cover 1 with a flat head screwdriver. $ remove the brake ...

  • Page 209: Partshark.Com

    Chassis 7-47 disconnect the brake breather hose. Remove the brake panel and panel cover 6 . Remove the o-ring 7 . Remove the brake cam lever 8 . Remove the brake lining indicator prate 9 , washer 0 and spring a . Remove the brake camshaft b and o-rings c from the brake panel. Partshark.Com 877-999-5...

  • Page 210: Partshark.Com

    7-48 chassis inspection brake drum measure the brake drum s i.D. To determine the extent of wear. If the measurement value exceeds the service limit, replace the brake drum with a new one. ' brake drum i.D. Service limit: 140.7 mm (5.54 in) brake shoe inspect the brake shoes for wear or damage. If a...

  • Page 211: Partshark.Com

    Chassis 7-49 remove the bearing with the special tool. % 09921-20240: bearing remover set $ reassembly and remounting install new bearing with the special tool. % 09913-70210: bearing installer set install the snap ring. Install new dust seal 2 to the drum cover 3 by using the removed dust seal 1 . ...

  • Page 212: Partshark.Com

    7-50 chassis apply suzuki super grease to new o-rings and brake camshaft. Install the o-rings and brake camshaft to the anchor panel. & 99000-25030: suzuki super grease a (usa) 99000-25010: suzuki super grease a (others) $ install the washer 4 . Install the spring 5 with the spring end hocked to the...

  • Page 213: Partshark.Com

    Chassis 7-51 install the brake panel to the rear axle housing. Install the panel cover 9 . Tighten the brake panel mounting nuts to the specified torque. " brake panel mounting nut: 60 n•m (6.0 kgf-m, 43.5 lb-ft) connect the brake breather hose. Note: make sure that the o-ring 8 must be fitted into ...

  • Page 214: Partshark.Com

    7-52 chassis install the brake drum. $ note: before installing the brake drum, make sure that the brake drum is clean and free of any greasey matter. Install the drum cover and tighten the bolts. Note: when installing the drum cover, make sure that the o-ring must be fitted into the groove on the br...

  • Page 215: Rear Shock Absorber

    Chassis 7-53 rear shock absorber construction removal raise the rear wheel off the ground and support the vehicle with a jack or wooden block. Remove the rear shock absorber 1 . Inspection rear shock absorber inspect the rear shock absorber body and rubber bushing for damage and leakage of oil. If a...

  • Page 216: Partshark.Com

    7-54 chassis rear shock absorber spacer and bearing remove the spacers and dust seals. $ inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones. Insert the spacer into the rear shock absorber bearing and then check the play by moving the spac...

  • Page 217: Partshark.Com

    Chassis 7-55 suspension setting spring pre-load adjustment the rear suspension spring pre-load is adjustable. This adjust- ment is performed by changing spring set length. Loosen the locknut 1 . Adjust the spring set length by turning the adjuster 2 . Spring set length a $ tighten the locknut 1 . Re...

  • Page 218: Rear Suspension

    7-56 chassis rear suspension construction item n•m kgf-m lb-ft a 78 7.8 55.0 b 60 6.0 43.5 c 85 8.5 61.5 d 60 6.0 43.5 ef 65 6.5 47.0 @ 1 rear shock absorber 2 swingarm 3 bearing a rear shock absorber mounting nut (upper) b rear shock absorber mounting nut (lower) c swingarm pivot nut d axle housing...

  • Page 219: Partshark.Com

    Chassis 7-57 removal remove the footrest mud guards. ( ! 7-7) remove the rear drive gear case assembly. ( ! 4-3) remove the rear shock absorber. ( ! 7-53) disconnect the brake breather hose 2 from the swingarm. Loosen the swingarm pivot bolts/nuts 3 . Remove the swingarm. Inspection and disassembly ...

  • Page 220: Partshark.Com

    7-58 chassis swingarm pivot bearing insert the spacer into the swingarm pivot bearings and then check the play by moving the spacer up and down. If excessive play is noted, replace the bearing with a new one. Remove the swingarm pivot bearing with the special tools. % 09923-74510: bearing remover 09...

  • Page 221: Partshark.Com

    Chassis 7-59 remounting remount the rear swingarm and suspension in the reverse order of removal. Pay attention to the following points: apply thread lock super to the swingarm pivot bolts. Install the swingarm pivot bolts and upper and lower shock absorber mounting bolts temporarily. Tighten the sw...

  • Page 222: Rear Axle

    7-60 chassis rear axle construction 1 rear axle 2 rear axle housing 65 n•m (6.5 kgf-m, 47 lb-ft) 60 n•m (6.0 kgf-m, 43.5 lb-ft) do not apply grease to the spline portion of the brake drum. Partshark.Com 877-999-5686.

  • Page 223: Partshark.Com

    Chassis 7-61 removal remove the rear wheels. ( ! 7-11) remove the rear wheel hubs. ( ! 7-11) remove the rear brake. ( ! 7-46) remove the rear axle housing/final gear case bolts 1 and rear axle housing set bolts/nuts 2 . Remove the rear axle housing 3 and rear axle 4 . Remove the o-ring 5 . Inspectio...

  • Page 224: Partshark.Com

    7-62 chassis rear axle housing inspect the rear axle housing for distortion or damages. If any damages are found, replace the rear axle housing with a new one. Reassembly and remounting reassemble and remount the rear axle in reverse order of removal and disassembly. Pay attention to the following p...

  • Page 225: Partshark.Com

    Chassis 7-63 rear wheel, rear brake, rear suspension, rear swin- garm and rear axle shaft reassembling information item n• m kgf-m lb-ft 1 85 8.5 61.5 2 78 7.8 56.0 3 60 6.0 43.5 4 60 6.0 43.5 5 50 5.0 36.0 6 138 13.8 96.6 7 11 1.1 8.0 8 60 6.0 43.5 9 65 6.5 47.0 @ 4 mm (0.16 in) 12 mm (0.47 in) 5 m...

  • Page 226: Partshark.Com

    7-64 chassis reverse lock release cable removal remove the reverse lock release knob 1 from the front fender. Open the fixed clamp. Remove the clip 2 and pin 3 . Loosen the locknuts 4 and remove the reverse lock release cable. Remove the bracket 5 . Remove the cap 6 . Partshark.Com 877-999-5686.

  • Page 227: Partshark.Com

    Chassis 7-65 remove the screw 7 and washers 8 . Remove the knob 9 . Disconnect the cable by removing the rotor 0 . Remounting remount the reverse lock release cable in the reverse order of removal. Pay attention to the following points: install the spring so that the spring end a matches the groove ...

  • Page 228: Partshark.Com

    7-66 chassis cable play adjustment after installing the reverse lock release cable, adjust the cable play. Loosen the locknuts 1 . Slide the adjuster 2 until the cable play at the reverse lock release knob a reaches 1 2 mm (0.04 0.08 in). Tighten the locknuts 1 securely. After adjustment, be sure to...

  • Page 229: Electrical System

    Electrical system 8-1 8 electrical system contents cautions in servicing ..........................................................................8- 2 connectors .......................................................................................8- 2 couplers .......................................

  • Page 230: Cautions In Servicing

    8-2 electrical system cautions in servicing connectors when disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. When connecting a connector, push it in so it is firmly attached. Inspect the connector for corrosion, contamination and any breakage in the cover. Coup...

  • Page 231: Partshark.Com

    Electrical system 8-3 battery the mf battery used in this vehicle does not require mainte- nance (e.G., electrolyte level inspection, distilled water replen- ishment). During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. There...

  • Page 232: Partshark.Com

    8-4 electrical system location of electrical components 1 cdi unit 2 battery 3 fuse 4 ignition switch 5 front brake light switch 6 rear brake light pedal switch 7 starter motor partshark.Com 877-999-5686.

  • Page 233: Partshark.Com

    Electrical system 8-5 1 handlebar switch (l) 7 ignition coil 2 rear brake light switch 8 generator 3 parking brake switch 9 neutral switch 4 neutral switch diode 0 regulator/rectifier 5 fuse a neutral relay 6 starter relay partshark.Com 877-999-5686.

  • Page 234: Charging System

    8-6 electrical system charging system trouble shooting battery runs down quickly. Step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed ? Step 2 1) check the battery for current leaks. ( ! 8-8) is the battery for current leaks ok ? Step 3 1) measure ...

  • Page 235: Partshark.Com

    Electrical system 8-7 step 4 1) measure the resistance of the generator coil. ( ! 8-9) is the resistance of generator coil ok ? Step 5 1) measure the generator no-load voltage. ( ! 8-9) is the generator no-load voltage ok ? Step 6 1) inspect the regulator/rectifier. ( ! 8-10) is the regulator/rectif...

  • Page 236: Partshark.Com

    8-8 electrical system inspection battery current leakage remove the seat. ( ! 7-5) turn the ignition switch to the off position. Disconnect the - battery lead wire 1 . Measure the current between the - battery terminal and the - battery lead wire using the multi circuit tester. If the reading exceed...

  • Page 237: Partshark.Com

    Electrical system 8-9 generator coil resistance remove the left fuel tank side cover. ( ! 7-5) disconnect the generator lead wire coupler. Measure the resistance among the three lead wires. If the resistance is not specified value, replace the stator coil with a new one. Also, check that the generat...

  • Page 238: Partshark.Com

    8-10 electrical system regulator/rectifier remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regu- lator/rectifier with a new one. $ 09900-25008: m...

  • Page 239: Starter System

    Electrical system 8-11 starter system trouble shooting starter motor will not run. Step 1 1) the transmission is in neutral. Turn on the ignition switch with the engine stop switch in the run posi- tion. 2) listen for a click from the starter relay when the starter button is pushed. Is a click sound...

  • Page 240: Partshark.Com

    8-12 electrical system step 3 1) measure the starter relay voltage at the starter relay connectors (between y/b + and b/w - ) when the starter button is pushed. Is the voltage ok ? Step 4 1) check the starter relay. ( ! 8-15) is the starter relay ok ? Note: the starter motor runs when the transmissi...

  • Page 241: Partshark.Com

    Electrical system 8-13 starter motor removal and disas- sembly remove the starter motor 1 . Disassembly the starter motor, as shown. Starter motor inspection carbon brushes inspect the carbon brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the ...

  • Page 242: Partshark.Com

    8-14 electrical system armature coil inspection check for continuity between each segment, and between each segment and the armature shaft using the multi circuit tester. If there is no continuity between the segments or there is conti- nuity between the segments and shaft, replace the armature with...

  • Page 243: Partshark.Com

    Electrical system 8-15 align the match marks on the starter motor case with the match mark on the housing end. Apply a small quantity of thread lock to the starter motor housing bolts and tighten it securely. 0 99000-32050: thread lock 1342 apply suzuki super grease to the o-ring. . 99000-25030: suz...

  • Page 244: Partshark.Com

    8-16 electrical system apply 12 v to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the relay is ok. $ 09900-25008: multi circuit tester set , tester knob indication: continuity t...

  • Page 245: Ignition System

    Electrical system 8-17 ignition system troubleshooting note: * check that the transmission is in neutral and the engine stop switch is in the run position. Check that the fuse is not blown and the battery is fully-charged before diagnosing. No spark or poor spark step 1 1) check the ignition system ...

  • Page 246: Partshark.Com

    8-18 electrical system step 3 1) measure the ignition coil primary peak voltage. ( ! 8-19) note: this inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage ok ? Step 4 1) inspect the spark plug. ( ! 2-7) are the spark plug ok ? Step 5 1) in...

  • Page 247: Partshark.Com

    Electrical system 8-19 inspection ignition coil primary peak voltage disconnect the spark plug cap. Connect a new spark plug to the spark plug cap and ground it to the cylinder head. Note: make sure that the spark plug cap and spark plug are connected properly and the battery is fully-charged. Measu...

  • Page 248: Partshark.Com

    8-20 electrical system ignition coil resistance disconnect the ignition coil lead wires and spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the s...

  • Page 249: Partshark.Com

    Electrical system 8-21 shift the transmission to the neutral position, turn the ignition switch to the on position. Press the starter button and allow the engine to turn for a few seconds, and then measure the pickup coil peak voltage. Repeat the above procedure a few times and measure the highest p...

  • Page 250: Lamps

    8-22 electrical system lamps headlight ! Headlight bulb replacement disconnect the coupler. Remove the bulb. Install new bulb in the reverse order of removal. Headlight beam adjustment adjust the headlight vertical beam by loosening the screw 1 . If you touch the bulb with your bare hands, clean the...

  • Page 251: Partshark.Com

    Electrical system 8-23 brake light/taillight " bulb replacement disconnect the socket. Remove the bulb. Install new bulb in the reverse order of removal. Brake light/taillight: 12 v 21/5 w e-28 only if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soa...

  • Page 252: Indicator Light

    8-24 electrical system indicator light inspection indicator light position re nu bl/r o/bl bl/b steering stem head cover item + - re: reverse indicator light o/bl bl/r nu: neutral indicator light o/bl bl/b bl/b bl/r o/bl : blue with black tracer : blue with red tracer : orange with blue tracer wire ...

  • Page 253: Diode

    Electrical system 8-25 diode remove the fuel tank left side cover. ( ! 7-5) remove the neutral switch diode 1 . Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. " 09900-25008: multi circuit tester set # tester knob indication: diode test ( $...

  • Page 254: Switches

    8-26 electrical system switches measure each switch for continuity using the multi circuit tester. If any abnormality is found, replace the respective switch assemblies with a new one. " 09900-25008: multi circuit tester set ignition switch dimmer switch engine stop switch starter button brake light...

  • Page 255: Battery

    Electrical system 8-27 battery specifications a anode plates e stopper b separator (fiberglass plate) f filter c cathode plates g terminal d upper cover breather h safety valve initial charging filling electrolyte remove the aluminum tape 1 sealing the battery electrolyte filler holes 2 . Remove the...

  • Page 256: Partshark.Com

    8-28 electrical system make sure that air bubbles 6 are coming up into each elec- trolyte container, and leave it in this position for more than 20 minutes. Note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the cont...

  • Page 257: Partshark.Com

    Electrical system 8-29 " servicing visually inspect the surface of the battery. If any signs of crack- ing or electrolyte leakage have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery termi...

  • Page 258: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 259: Servicing Information

    9 servicing information 9-1 contents servicing information troubleshooting .................................................................................. 9- 2 engine .................................................................................................. 9- 2 drive train .................

  • Page 260: Troubleshooting

    9-2 servicing information troubleshooting engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Worn cylinder. 2. Worn piston ring. 3. Worn valve guide or improper valve seating. 4. Loose spark plug. 5. Slow cranking starter motor. 6. M...

  • Page 261: Partshark.Com

    Servicing information 9-3 complaint symptom and possible causes remedy engine is noisy. Noise seems to come from the crankshaft 1. Worn or burnt bearing. 2. Big-end bearing worn or burnt. 3. Excessive thrust clearance. Noise seems to come from transmission 1. Gears worn or rubbing. 2. Badly worn spl...

  • Page 262: Partshark.Com

    9-4 servicing information complaint symptom and possible causes remedy engine idles poorly. 1. Valve clearance out of adjustment. 2. Poor seating of valves. 3. Defective valve guides. 4. Worn rocker arm or arm shaft. 5. Defective generator. 6. Defective cdi unit. 7. Spark plug gap too wide. 8. Defec...

  • Page 263: Partshark.Com

    Servicing information 9-5 drive train carburetor complaint symptom and possible causes remedy power will not trans- mit from the engine to the rear wheel. 1. Broken drive and driven bevel gear teeth. 2. Broken propeller shaft serration. 3. Worn or broken rear axle serration. 4. Worn or damaged coupl...

  • Page 264: Partshark.Com

    9-6 servicing information chassis complaint symptom and possible causes remedy handling is too heavy or stiff. 1. Improper front wheel alignment. 2. Insufficiently lubricated. 3. Low air pressure in front tires. 4. Tie rod ends tending to seize. 5. Linkage connections tending to seize. Adjust. Lubri...

  • Page 265: Partshark.Com

    Servicing information 9-7 brakes complaint symptom and possible causes remedy poor braking. (front) 1. Insufficient brake fluid. 2. Air in brake fluid circuit. 3. Worn pads. 4. Worn disc. Refill to level mark. Bleed air out. Replace. Replace. Poor braking. (rear) 1. Worn shoe linings. 2. Too much pl...

  • Page 266: Partshark.Com

    9-8 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking. 1. Defective ignition coil. 2. Defective spark plug. 3. Defective generator. 4. Defective cdi unit. 5. Defective pickup coil. Replace. Replace. Replace. Replace. Replace. Spark plug is wet...

  • Page 267: Partshark.Com

    Servicing information 9-9 battery complaint symptom and possible causes remedy sulfation or spots on surfaces of cell plates. 1. Cracked battery case. 2. Battery has been left in a run-down condition for a long time. Replace. Replace. Battery runs down quickly. 1. Incorrect charging method. 2. Batte...

  • Page 268: Wiring Diagram

    9-10 servicing information wiring diagram hi lo run off push cdi unit regulator/ rectifier fuse box ignition coil tail light battery 1 fuse : 20a starter motor starter relay 1 neutral diode generator neutral relay neutral switch ignition switch headlight light on off r o gr brake light switch (r) br...

  • Page 269: Partshark.Com

    Servicing information 9-11 wiring harness, cable, and hose routing wiring harness routing ignition coil clamp wiring harness handlebar switch ignition swich reverse cable clamp wiring harness battery + clamp brake light/taillight clamp parking brake pilot lamp left brake switch ec approval label (e-...

  • Page 270: Partshark.Com

    9-12 servicing information ( ) forward clamp clamp clamp 30ß generator lead wire starter motor lead wire neutral switch lead wire starter motor starter motor c starter motor lead wire view a view b clamp handlebar switch (l) parking brake switch starter cable brake lever switch ignition switch pass ...

  • Page 271: Partshark.Com

    Servicing information 9-13 cable routing throttle cable clamp parking brake cable brake hose reverse cable pass the throttle cable in front of the parking brake cable. Pass the parking brake cable behind the brake hose. Starter cable clamp e parking brake cable starter cablle pass the reverse cable ...

  • Page 272: Partshark.Com

    9-14 servicing information detail g outside reverse cable front set the pin outside reverse cable pin detail f outside front clamp the starter cable with the wiring harness. Clamp wiring harness starter cable clamp the starter cable inside of the frame. F starter cable clamp parking brake cable pass...

  • Page 273: Partshark.Com

    Servicing information 9-15 steering shaft set-up tighten the rear bolts after tightening the front ones. Clearance partshark.Com 877-999-5686.

  • Page 274: Partshark.Com

    9-16 servicing information carburetor hose routing air vent hose carburetor clamp clamp carburetor overflow hose left right left right 45ß partshark.Com 877-999-5686.

  • Page 275: Partshark.Com

    Servicing information 9-17 front brake hose routing f ront br ak e hose cab le guide view c view d view b sect ee (lh) (rh) re v erse cab le a p ass the br ak e hose in front of the wir ing har ness . Throttle cab le b f f e e f o w ard br ak e hose guide clamp fir mly . After the br ak e hose union...

  • Page 276: Partshark.Com

    9-18 servicing information rear brake breather hose routing rear s wingar m p ass through the rear br ak e breather hose into the hole of the fuel tank plate . View a view h sect ff , gg sect ee view b sect cc rear br ak e breather hose clip inside outside rear br ak e breather hose g g f f e b a e ...

  • Page 277: Partshark.Com

    Servicing information 9-19 fuel hose routing steer ing head co v er fuel tank breather hose no . 2 fuel tank breather hose fuel tank spacer cushion a cushion frame fuel tank front cushion clip fuel hose clip 4.5 nÆ m (0.45 kgf-m, 3.25 lb-ft) steer ing head co v er connect the wide diameter side of t...

  • Page 278: Partshark.Com

    9-20 servicing information rear brake cam lever set-up br ak e panel spr ing br ak e lining indicator plate w asher br ak e cam shaft br ak e lining indicator plate align the tongue on the indicator plate with the elimination of one tooth of the br ak e cam shaft. Align the punched mar k on the br a...

  • Page 279: Steering Head Cover Set-Up

    Servicing information 9-21 steering head cover set-up steering head cover clip steering head cover bracket fuel tank breather hose no. 2 partshark.Com 877-999-5686.

  • Page 280: Taillight Set-Up

    9-22 servicing information taillight set-up rear fender taillight side reflector rear reflector e-28 only partshark.Com 877-999-5686.

  • Page 281: Special Tools

    Servicing information 9-23 special tools 09900-00410 hexagon wrench set 09900-06106 snap ring pliers 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09004 impact driver set 09900-20101 vernier calipers 09900-20202 micrometer (1/100 mm, 25 50 mm) 09900-20203 micrometer (1/100 mm, 50 7...

  • Page 282: Partshark.Com

    9-24 servicing information 09913-85210 bearing/oil seal installer 09915-64510 compression gauge set 09918-02410 or 09918-03810 (adaptor) 09915-74511 oil pressure gauge 09915-74512 oil pressure gauge adaptor 09916-10911 valve lapper set 09916-14510 valve spring com- pressor 09916-14910 valve spring c...

  • Page 283: Partshark.Com

    Servicing information 9-25 note: when ordering a special tool, please confirm whether it is available or not. 09930-10121 spark plug wrench set 09930-30721 rotor remover 09930-35010 rotor remover 09930-31921 rotor remover 09930-44520 rotor holder 09930-73150 output shaft holder 09950-81910 remover p...

  • Page 284: Tightening Torque

    9-26 servicing information tightening torque engine item n•m kgf-m lb-ft cylinder head cover bolt 10 1.0 7.0 camshaft sprocket bolt 11 1.1 8.0 cylinder head nut (m8) 23 2.3 16.5 cylinder head nut (m6) 10 1.0 7.0 cylinder base nut (m6) 10 1.0 7.0 cam chain tensioner mounting bolt 10 1.0 7.0 cam chain...

  • Page 285: Partshark.Com

    Servicing information 9-27 drive train chassis item n•m kgf-m lb-ft final gear case cover bolt 26 2.6 19.0 pinion gear bearing locknut 100 10.0 72.5 rear drive gear oil filler plug 26 2.6 19.0 rear drive gear oil drain plug 26 2.6 19.0 rear axle housing set bolt/nut (rh) 60 6.0 43.5 rear axle housin...

  • Page 286: Partshark.Com

    9-28 servicing information tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a a a a (mm) conventional or 4 marked bolt 7 marked bolt n•m kgf-m lb-ft n•m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4....

  • Page 287: Service Data

    Servicing information 9-29 service data valve + guide unit: mm (in) item standard limit valve diam. In. 32 (1.3) ex. 28 (1.1) tappet clearance (when cold) in. 0.03 0 .08 (0.001 0 .003) ex. 0.08 0 .13 (0.003 0 .005) valve guide to valve stem clearance in. 0.010 0 .037 (0.0004 0 .0015) ex. 0.030 0 .05...

  • Page 288: Partshark.Com

    9-30 servicing information camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.780 33.820 (1.3299 1.3315) 33.480 (1.3181) ex. 32.990 33.030 (1.2988 1.3004) 32.690 (1.2870) camshaft journal oil clearance 0.036 0.066 (0.0014 0.0026...

  • Page 289: Partshark.Com

    Servicing information 9-31 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring thickness 1st 0.97 0.99 (0.038 0.039) 2nd 1.17 1.19 (0.046 0.047) piston pin bore 16.002 16.008 (0.6300 0.6302) 16.030 (0.6311) piston pin o.D. 15.992 16.000 (0.6296 0.6299) 15....

  • Page 290: Partshark.Com

    9-32 servicing information drive train unit: mm (in) except ratio carbretor item standard limit primary reduction ratio 3.047 (64/21) secondary reduction ratio 1.133 (17/15) final reduction ratio 3.200 (32/10) gear ratios 1st 3.083 (37/12) 2nd 1.933 (29/15) 3rd 1.388 (25/18) 4th 1.095 (23/21) 5th 0....

  • Page 291: Partshark.Com

    Servicing information 9-33 electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: dr7ea denso: x22esr-u gap 0.6 0.7 (0.024 0.028) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.05 1.0 Ω Ω Ω Ω terminal terminal secondary 10.5 1 9.0 k Ω Ω Ω Ω...

  • Page 292: Partshark.Com

    9-34 servicing information brake + wheel unit: mm (in) tire pressure vehicle load capacity limit: 110 kg (243 lbs) item standard/specification limit rear brake lever play 3 5 (0.12 0.20) rear brake pedal free travel 20 30 (0.79 1.18) brake disc thickness front 2.8 3.2 (0.110 0.126) 2.5 (0.098) brake...

  • Page 293: Partshark.Com

    Servicing information 9-35 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10 % ethanol, or less than 5 % methanol wit...

  • Page 294: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 295: Lt-Z250K5 ( 05-Model)

    Lt-z250k5 ( 05-model) 10-1 contents lt-z250k5 ( 05-model) 10 this chapter describes specifications, service data and servicing procedures which differ from those of the lt-z250k4 ( 04-model). Note: * any differences between the lt-z250k4 ( 04-model) and lt-z250k5 ( 05-model) in specifications and se...

  • Page 296: Specifications

    10-2 lt-z250k5 ( 05-model) specifications dimensions and dry mass overall length ...................................................................................... 1 720 mm (67.7 in) overall width ....................................................................................... 1 070 mm (4...

  • Page 297: Service Data

    Lt-z250k5 ( 05-model) 10-3 service data valve + guide unit: mm (in) item standard limit valve diam. In. 32 (1.3) ex. 28 (1.1) tappet clearance (when cold) in. 0.03 0.08 (0.001 0.003) ex. 0.08 0.13 (0.003 0.005) valve guide to valve stem clearance in. 0.010 0.037 (0.0004 0.0015) ex. 0.030 0.057 (0.00...

  • Page 298: Partshark.Com

    10-4 lt-z250k5 ( 05-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.780 33.820 (1.3299 1.3315) 33.480 (1.3181) ex. 32.990 33.030 (1.2988 1.3004) 32.690 (1.2870) camshaft journal oil clearance 0.036 0.066 (0.0014 0.0026...

  • Page 299: Partshark.Com

    Lt-z250k5 ( 05-model) 10-5 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 16.006 16.014 (0.6302 0.6305) 16.040 (0.6315) conrod deflection 3.0 (0.12) conrod big end side clearance 0.10 0.45 (0.004 0.018) 1.0 (0.04) conrod big end width 17.95 ...

  • Page 300: Partshark.Com

    10-6 lt-z250k5 ( 05-model) drive train unit: mm (in) except ratio carbretor item standard limit primary reduction ratio 3.047 (64/21) secondary reduction ratio 1.133 (17/15) final reduction ratio 3.200 (32/10) gear ratios 1st 3.083 (37/12) 2nd 1.933 (29/15) 3rd 1.388 (25/18) 4th 1.095 (23/21) 5th 0....

  • Page 301: Partshark.Com

    Lt-z250k5 ( 05-model) 10-7 electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: dr7ea denso: x22esr-u gap 0.6 0.7 (0.024 0.028) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.05 1.0 Ω terminal terminal secondary 10.5 19.0 k Ω plug cap ter...

  • Page 302: Partshark.Com

    10-8 lt-z250k5 ( 05-model) brake + wheel unit: mm (in) tire pressure vehicle load capacity limit: 110 kg (243 lbs) item standard/specification limit rear brake lever play 3 5 (0.12 0.20) rear brake pedal free travel 20 30 (0.79 1.18) brake disc thickness front 2.8 3.2 (0.110 0.126) 2.5 (0.098) brake...

  • Page 303: Partshark.Com

    Lt-z250k5 ( 05-model) 10-9 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol with ...

  • Page 304: Tightening Torque

    10-10 lt-z250k5 ( 05-model) tightening torque chassis front brake caliper mounting bolt apply thread lock super 1360 to the caliper mounting bolts before tightening them. 99000-32130: thread lock super 1360 item n•m kgf-m lb-ft handlebar clamp bolt 23 2.3 16.5 steering shaft holder bolt 23 2.3 16.5 ...

  • Page 305: Front Brake Hose Routing

    Lt-z250k5 ( 05-model) 10-11 front brake hose routing f ront br ak e hose cab le guide view c view d view b sect e e (lh) (rh) re v erse cab le a p ass the br ak e hose in front of the wir ing har ness . Throttle cab le b f f e e f o w ard br ak e hose guide clamp fir mly . After the br ak e hose uni...

  • Page 306: Partshark.Com

    Partshark.Com 877-999-5686.

  • Page 307: Lt-Z250K6 ( 06-Model)

    Lt-z250k6 ( 06-model) 11-1 contents lt-z250k6 ( 06-model) 11 this chapter describes specifications, service data and servicing procedures which differ from those of the lt-z250k5 ( 05-model). Note: * any differences between the lt-z250k5 ( 05-model) and lt-z250k6 ( 06-model) in specifications and se...

  • Page 308: Specifications

    11-2 lt-z250k6 ( 06-model) specifications dimensions and dry mass overall length ...................................................................................... 1 720 mm (67.7 in) overall width ....................................................................................... 1 070 mm (4...

  • Page 309: Service Data

    Lt-z250k6 ( 06-model) 11-3 service data valve + guide unit: mm (in) item standard limit valve diam. In. 32 (1.3) ex. 28 (1.1) tappet clearance (when cold) in. 0.03 0.08 (0.001 0.003) ex. 0.08 0.13 (0.003 0.005) valve guide to valve stem clearance in. 0.010 0.037 (0.0004 0.0015) ex. 0.030 0.057 (0.00...

  • Page 310: Partshark.Com

    11-4 lt-z250k6 ( 06-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.780 33.820 (1.3299 1.3315) 33.480 (1.3181) ex. 32.990 33.030 (1.2988 1.3004) 32.690 (1.2870) camshaft journal oil clearance 0.036 0.066 (0.0014 0.0026...

  • Page 311: Partshark.Com

    Lt-z250k6 ( 06-model) 11-5 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring thickness 1st 0.97 0.99 (0.038 0.039) 2nd 1.17 1.19 (0.046 0.047) piston pin bore 16.002 16.008 (0.6300 0.6302) 16.030 (0.6311) piston pin o.D. 15.992 16.000 (0.6296 0.6299) 15....

  • Page 312: Partshark.Com

    11-6 lt-z250k6 ( 06-model) drive train unit: mm (in) except ratio carbretor item standard limit primary reduction ratio 3.047 (64/21) secondary reduction ratio 1.133 (17/15) final reduction ratio 3.200 (32/10) gear ratios 1st 3.083 (37/12) 2nd 1.933 (29/15) 3rd 1.388 (25/18) 4th 1.095 (23/21) 5th 0....

  • Page 313: Partshark.Com

    Lt-z250k6 ( 06-model) 11-7 electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: dr7ea denso: x22esr-u gap 0.6 0.7 (0.024 0.028) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.05 1.0 Ω terminal terminal secondary 10.5 19.0 k Ω plug cap ter...

  • Page 314: Partshark.Com

    11-8 lt-z250k6 ( 06-model) brake + wheel unit: mm (in) tire pressure vehicle load capacity limit: 110 kg (243 lbs) item standard/specification limit rear brake lever play 3 5 (0.12 0.20) rear brake pedal free travel 20 30 (0.79 1.18) brake disc thickness front 2.8 3.2 (0.110 0.126) 2.5 (0.098) brake...

  • Page 315: Partshark.Com

    Lt-z250k6 ( 06-model) 11-9 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol with ...

  • Page 316: Lt-Z250K7 ( 07-Model)

    Contents note: lt-z250k7 ( 07-model) 12-1 lt-z250k7 ( 07-model) * the specification and service data are the same as the k6-model 12 i nformation label installation (for e-33) ................................... 12- 2 partshark.Com 877-999-5686.

  • Page 317: Partshark.Com

    – 2 – information label installation (for e-33) 10 ± 5 mm label frame lh side 12- 2 lt-z250k7 ( 07-model) partshark.Com 877-999-5686.

  • Page 318: Lt-Z250K8 ( 08-Model)

    Contents note: lt-z250k8 ( 08-model) 13-1 lt-z250k8 ( 08-model) * the specification and service data are the same as the k7-model 13 i nformation label ............................................................................... 13- 2 partshark.Com 877-999-5686.

  • Page 319: Information Labels

    – 2 – information labels * e-28: fuel caution label enclosed. E : english f : french a: attached no. Label or plate name applied specification e-19 e-28 e-33 1 certification plate e a a 2 information label e a 3 gearshift pattern label e a 4 gearshift pattern label e / f a 5 tire air pressure label ...

  • Page 320: Lt-Z250K9  (’09 Model)

    Contents 6jkuejcrvgtfguetkdguugtxkegurgekhkecvkqpuugtxkegfcvccpfugtxkekpirtqegfwtgtuyjkej fkhhgthtqovjqugqhvjg.6- ŏ/1&'. 016' #p[fkhhgtgpegudgvyggpvjg.6- ŏ/1&'.Cpf.6- ŏ/1&'. Kpurgekhkecvkqpuctgengct[kpfkecvgfykvjcpcuvgtkum octm 2ngcugtghgtvqvjgecrvgtuvjtqwijhqtfgvcknuyjkejctgpqvikxgpkpvjkuejcrvgt pa...

  • Page 321: Specifications

    Specifications dimensions and curb mass overall length ...................................................................................... 1 720 mm (67.7 in) overall width........................................................................................ 1 070 mm (42.1 in) overall height ......

  • Page 322: Service Data

    Service data carbretor fuel + oil item specification * e-19 * e-28, 33 carburetor type mikuni bsr29 ← bore size 29 mm (1.14 in) ← i.D. No. 21g0 21g1 idle r/min 1 500 ± 100 r/min ← float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ← main jet (m.J.) #125 # jet needle (j.N.) 5dh54-2nd ← needle jet (n.J.) p-0...

  • Page 323: Fuel Tank Construction

    Fuel tank construction 1 fuel tank 2 fuel cap 3 breather hose 4 gasket 5 gasket 6 fuel valve 7 fuel hose 14- 4 lt-z250k9 ( 09-model) partshark.Com 877-999-5686.

  • Page 324: Carburetor

    Carburetor pilot screw removal (for e-28, 33) because harsh cleaning solvents can damage the o-ring seals in the pilot system, the pilot system components should be removed before cleaning. • use a 1/8” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 4 mm (0.16 in...

  • Page 325: Information Labels

    Information labels information label (e-28) certification label (e-33) front of frame right side fwd 14- 6 lt-z250k9 ( 09-model) partshark.Com 877-999-5686.